1. The Gas Engine 20V35/44G by MAN Diesel & Turbo SE
4/1/2017
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2. Disclaimer
4/1/2017
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3. The Gas Engine 20V35/44G by MAN Diesel & Turbo SE Agenda:
Gas Engine Portfolio of MAN Diesel & Turbo SE
20V35/44G - Main Technical Data
Technical Features and Innovations
Gas Specification and Exhaust Emissions
Applications
Operational Behaviour
Summary

4. Starting of Assembly of new MAN Gas Engine 20V35/44G in Augsburg (Jan

5. 20V35/44G – Project Status:
Engine on Test bed (10/ /2013)

6. MAN Diesel & Turbo Stationary Gas Engine Portfolio
51/60G rpm
18.9 MW
Gas Engines (Spark ignited
35/44G rpm
10.6 MW
32/40G rpm
8.1 MW
51/60DF rpm
8.8 – 17.6 MW
Dual Fuel Engines
32/40DF rpm
3.6 – 7.2 MW
Power 50 Hz [MWm] 2 4 6 8 10 12 14 16 18 20 22 24

7. Properties of Gas Engine 20V35/44G
Otto Combustion Process with Lean Burn Principle (Spark Ignited)
Natural Gas as Fuel (Low Pressure Gas Supply)
Progressive Engine Design with Newest Methods and Tools
Single Stage Turbocharging with Variable Turbine Area (VTA)
Waste Heat Utilization for Combined Cycle (CC) and Combined Heat and Power (CHP)
Reliable Safety System
High Power Output per Engine for Low Engine Cost
High Efficiencies for Low Operating Cost
Low Exhaust Emissions Compliant to all Relevant Legislations
Low Maintenance Cost
High Maintainability and MAN proven Robustness
High Availability
Results

8. Main Technical Data 20V35/44G
Specification
Dimension
Value 50 Hz
Value 60 Hz
Bore / Stroke mm
350 / 440
Swept Volume
litre
42,3
V - angle 55
Speed
rpm
750
720
Cyl. Output
kWm/Cyl.
530
510
bmep
bar 20
Engine Output
kWm
10.600
10.200
Efficiency
TA-Luft, MN = 80, 100 % load, cos  = 0,9 5 % tolerance, ISO Cond. (25 °C, 1 bar) with attached pumps
kJ/kWhel
%el
7,621
47.2
Height
4.500
Width
3.850
Length
9.900
Weight (dry)
tons
113,5

9. Key Dimensions Engine 20V35/44G
4.500 mm
9.900 mm
4.450 mm
Mass (dry): 113,5 t

10. Generator Set Dimensions 20V35/44G
Mass (dry): tons (Engine: t, Coupling: 1.0 t, Generator: 30.5 t)

11. Technical Features and Innovations 20V35/44G
Safety System: active monitoring, knocking control, pressure relief valves
Turbocharger Assembly: modular concept, central exhaust housing, braced on base frame
Electronics, Cabling: On-Engine-Concept, cable looms, connectors/clips
Interfaces to Plant gas system, coolant system, oil system are located on counter coupling side
Lambda Control: VTA, wastegate, compressor bypass
Starting System: air pressure starter, slow turn function
Base Frame: integral part of engine, (oil pan, structure stiffness)

12. Technical Features and Innovations 20V35/44G
Valvetrain: improved gas exchange, central camshaft, swing and rocker arms
Exhaust Pipe: ceramics foam isolated, reduced flow losses
Combustion Process: lean burn Otto process, Miller cycle high efficiency, wide operation area
Ignition System: gas flushed prechamber, spark plug, gas admission valves Ignition Energy Control
Cranktrain: lightweight train with high efficiency MAN piston development,
Crankcase: short main tie rods, high stiffness, V-angle 55 °

13. The Gas Engine 20V35/44G Pre-chamber Spark Ignition Principle
Ignition Process:
Main combustion chamber will be filled with lean mixture of natural gas and air
Prechamber will be flushed with natural gas (rich mixture within prechamber)
Compression by upward piston motion (checkvalve prevents gas losses)
Spark plug initiates the ignition within prechamber
Flames coming out of the prechamber start combustion within main combustion chamber

14. 20V35/44G Engine Controls “SaCoS_one”
EXHAUST
AIR
SACOS one
ENGINE CONTROL
- LAMBDA CONTROL
- GVU CONTROL
- LOAD CONTROL
SAFETY SYSTEM
ALARM SYSTEM
SACOS one
KNOCK CONTROL UNIT
MAIN GVU GAS VALVE UNIT
The engine is equipped with the sacos one system.
On this diagram you
SACOS one
IGNITION UNIT
PRECHAMBER GVU GAS VALVE UNIT
SACOS one
INJECTION UNIT G

15. The world-wide strongest 10 MW gas engine from MAN Diesel & Turbo
Length incl. Generator: 14m
High: 4,5m
Width: 4,5m
Weight: 145t
47.2% electrical efficiency

16. 20V35/44G Released Fuel Gas Specification
MN [ - ]
Biogas [23/133]
Fuel Specification (Natural Gas):
Lower Heating Value (LHV): > 32,4 MJ/mN³
Sulfur: < 30 mg/mN³
H2S: < 5 mg/mN³
Fluoride: < 5 mg/mN³
Chlorine: < 10 mg/mN³
Clean and dry
130
120
110
Rated Power
100
Methane [36/100]
Natural Gas H [36/92] 90
Natural Gas L [32/88] 80
Efficiency Reduction
and possibly Power Derating 70 60
No Operation 50
Ethane C2H6 [65/44] 40
Propane C3H8 [93/34] 30 20
Propene C3H6 [88/19]
Ethene C2H4 [60/15]
Butane C4H10 [124/10] 10 10 20 30 40 50 60 70 80 90
100
110
120
LHV [MJ/mN³]

17. 20V35/44G Exhaust Gas Emissions
Emission Legislation for Spark Ignited Gas Engines (Excerpt):
NOx
THC CO
HCHO
SO2
NMHC
Note
5 % O2]
TA-Luft
5 % O2)
500 -
300 60
EU Directive (IED / IPPC 1))
15 % O2)
200
(75)
266
(100)
Will come into effect 2013;
Exhaust Gas Aftertreatment (SCR) possible for higher effic.
1) Industrial Emissions Directive / Integrated Pollution Prevention and Control
Emissions Compared to Diesel HFO Engines:
CO2: - 25 %
NOx: - 80 %  additional SCR-Catalyst possible, if desired
CO: + 20 %  Oxidation Catalyst
Particles / SO2: - 99 %

18. 20V35/44G Operational Behaviour

19. 20V35/44G Operational Behaviour
Reference Conditions: - Air Temperature / Pressure: 25 °C / mbar (ISO ) - Relative Humidity: 30 % - Charge Air Temperature: 43 °C - Exhaust Gas Backpressure: 30 mbar - Methane Number (Natural Gas) ≥ 80
Fuel Gas Specification (Standard Engine Design)
TCA = 43 °C
TCA = 50 °C
Water Inlet Temp. of
Charge Air Cooler Stage 2

20. 20V35/44G Operational Behaviour
Example:
Tair,max = + 30 °C
Compensation of Ambient Temperature
Fluctuations
 Full Power Output w/o Derating
Tair,min = - 10 °C
20V35/44G
Base Load [kWm]
Load Step [kWm]
1.900
(25 %) 2.600
(50 %) 5.300
1.700
(75 %) 8.000
1.300
(90 %) 9.500
800
Load Steps at
Island Mode

21. 20V35/44G for CHP Applications Hot water generation, e.g. 60/125°C

22. 20V35/44G for CHP Applications Steam and Hot Water Generation

23. 20V35/44G for CHP Applications Thermal Output and Temperature Levels
Heat balance for the 20V35/44G -> case, district heating 60°C/125°C Fuel input: 22,5 MWth ; Recoverable thermal output: 9,8 MWth (above 60°C)
Exhaust gas
Charge air cooler 1
Charge air cooler 2
Lube oil cooler
Jacket cooling
water
Power in kWth
4,965
1,830
620
1,100
1,400
Temperature level in primary circuit
(in/out °C)
370/120
85/96
73/77
65/76
77/85
Flow in primary circuit
65 t/h
140 m³/h
200 m³/h
Tamb: 25°C; pamb : 1000 mbar; Back pressure: 30 mbar; Attached pumps: 1x lube oil, 2x cooling water; Methane number: >80

24. 20V35/44G for CHP Applications CHP – Performance Statement
Heat balance for the 20V35/44G -> case, hot water 60°C/125°C - Fuel input: 22,5 MWth - Recoverable thermal output: 9,8 MWth ; - Electrical Output: 10,34 MWel
Efficiency
Excellent CO2 statement
In CHP: 225 g/kWh
Electricity only: 439 g/kWh
Alpha number: 1,1 (“Stromkennzahl”)
43.6%
89.6%
46.0%
Eta Total
Eta electrical plus heat
Based on 20V35/44G ISO-3046 conditions;
89.6% total efficiency for hot water applications – high efficient gas engine plus efficient waste heat utilisation

25. 20V35/44G for Combined Cycle Engine Combined Cycle - System Overview
25 bar
360 °C
Waste heat potential
- exhaust gas
- cooling water
Exhaust Gas
- ca. 30% of fuel input
- ca. 340°C – 370°C
- used for steam generation
High temperature cooling water
- ca. 13% of fuel input
- 90°C
- used for condensate preheating,
- preheating of aux. consumers
26 bar
0,16 bar
55 °C
4 bar
144 °C
4,5 bar
3,6 bar
140 °C
120 °C

26. 20V35/44G for Combined Cycle Engine Combined Cycle - Concept
MAN diesel / gas engines
Concept of the Combined Cycle Package
Boost the efficiency of a power plant with Gas engines by adding heat recovery steam generators and a steam turbine
MAN Diesel & Turbo’s steam turbine family is optimised for CC applications
MAN RENK gearbox
System is modular, easy to commission, easy to operate
Increase of plant efficiency up to 5%
Increase of power output up to 13%
MAN steam turbine
Strong Synergy : In-house Engine and Turbine Technology

27. Combined Cycle Applications MAN MARC Steam Turbines

28. 20V35/44G Summary – Your Benefits
Reliable Power Source kWm Rated Power (50Hz)
Low Fuel Cost 47.2 % Electrical efficiency Simple cycle
50.4 % Electrical efficiency Combined cycle
Heat Utilization (District heating) ~90 % Total CHP efficiency
Short Power Ramp Up Time 100 % Load within 5 Minutes
Changing Ambient Conditions Tair = 40 Kelvin without Power Derating
Ease of Maintenance / High Availability
Simple & fast exchange of spark plugs
High Safety Standards
Active monitoring, Safety devices, CE conformity

29. Q&A